EP1662033B1 - Verfahren und vorrichtung zur herstellung eines verstärkungsgewebes - Google Patents

Verfahren und vorrichtung zur herstellung eines verstärkungsgewebes Download PDF

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Publication number
EP1662033B1
EP1662033B1 EP03818577A EP03818577A EP1662033B1 EP 1662033 B1 EP1662033 B1 EP 1662033B1 EP 03818577 A EP03818577 A EP 03818577A EP 03818577 A EP03818577 A EP 03818577A EP 1662033 B1 EP1662033 B1 EP 1662033B1
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EP
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Prior art keywords
woven fabric
yarn
reinforcing fiber
warp
producing
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EP03818577A
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English (en)
French (fr)
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EP1662033A4 (de
EP1662033A1 (de
Inventor
Kiyoshi Homma
Akira Nishimura
Ikuo Horibe
Eisuke Wadahara
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Toray Industries Inc
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Toray Industries Inc
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics

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  • the invention relates to the improvement of a method for producing a reinforcing fiber woven fabric and an apparatus thereof. Particularly, the invention relates to the improvement of a method for producing a reinforcing fiber and an apparatus adding an improvement to the widening of the yarn width when producing a reinforcing fiber woven fabric useful as a base material for fiber reinforced plastics
  • woven fabric Conventionally, one having a form of woven fabric has been abundantly used as an intermediate base material when producing a fiber reinforced plastic.
  • a thin reinforcing fiber yarn is used for a warp and a weft so as to reduce crimp due to the interlacing of the warp and weft as much as possible to exhibit high intensity expression.
  • the reinforcing woven fabric Since a thin yarn causes the low productivity of the yarn itself and woven fabric when the reinforcing fiber is particularly a carbon fiber yarn, the reinforcing woven fabric and has been mainly used for an airplane use or the like having large weight saving effect.
  • the woven fabric is used and formed into a fiber reinforced composite material molded object (hereinafter, referred to as molded object), the molded object in which the resin is unevenly dispersed between the weaving yarns is obtained.
  • molded object fiber reinforced composite material molded object
  • the molded object having the high content of the carbon fiber is not obtained. Also, when the stress acts on the molded object, a portion in which the resin is unevenly dispersed becomes the starting point of destruction, and high mechanical property is not exhibited.
  • Examples of the factors in which the gap is formed between the weaving yarns include the followings.
  • JP-A Japanese Patent Application Laid-Open
  • the yarn bundle of the weaving yarn is converged as the section of the bundle is almost a circular shape in the woven fabric in which the thin carbon fiber yarn having the number of filaments of about 3,000 is woven in the small weaving yarn pitch, the yarn width is widened by pushing the weaving yarn at the convex part of the spherical body, and the opening is closed.
  • the convex part of the spherical body (central part of the ball) may be located between the flat weaving yarns. Since the convex part of the spherical body is rolled between the weaving yarns in that condition, the operation for enlarging the gap between the weaving yarns acts, and the yarn width is narrowed on the contrary. Since the rotation of the spherical body is not lightly rotated by friction with a positioning mesh, the woven fabric slippage is easily generated by the movement of the spherical body in the flat yarn woven fabric where the binding force between the warp and the weft is weak and the woven fabric slippage is easily and simply generated.
  • FR 2 478 693 discloses a reinforcing fibre woven fabric impregnated with resin using graphite fibres and a method for producing the same for providing an elevated modulus of elasticity of the fabric.
  • FR 2 478 693 also discloses an apparatus for producing the woven fabric which comprises a plurality of cylindrical bodies rotatably supported on the woven fabric while it passes over a plate and driving means for reciprocating the cylindrical bodies in the direction of the warp of the woven fabric.
  • the method for producing the reinforcing fiber woven fabric of the invention is as follows.
  • the method comprises the step of reciprocating a cylindrical body in the direction of the warp of the woven fabric on the woven fabric while the cylindrical body is rolled in a pressurization state to the woven fabric to widen the yarn width at least of the warp constituting the woven fabric in the direction of a weft, whereby the cylindrical body is reciprocated on the woven fabric which comes into contact with a guide roller while moving the woven fabric along the surface of the guide roller capable of being rotated.
  • the pressure force of the cylindrical body to the woven fabric is preferably 100 to 2000 g per 1 cm of the length of the axial direction of the cylindrical body.
  • a widening rate for widening the yarn width of the warp in the direction of the weft is preferably 2 to 50%.
  • the reinforcing fiber is preferably a carbon fiber.
  • the number of filaments of the carbon fiber is preferably 6000 to 50000.
  • the woven fabric is moved in the direction of the warp along the surface of a guide roller capable of being rotated to continuously widen the yarn width of the woven fabric contacting with the surface of the guide roller.
  • the yarn width is preferably widened between a cloth fell of a loom and a winding roll of the woven fabric.
  • an average speed for reciprocating the cylindrical body is set at 50 to 300 mm/second.
  • the woven fabric is a flat yarn woven fabric having a warp and a weft consisting of a carbon fiber yarn and having a flat woven fabric of plain weave, the method comprising the steps of: opening and widening the weft by air jet injection from injection holes aligned in the direction of the weft of the woven fabric; and widening the warp yarn width in the direction of the weft by one of the above methods.
  • the method for producing the reinforcing fiber woven fabric comprising: a weaving step of weaving a woven fabric while inserting a low melting point resin fiber in the direction of a warp or a weft; a widening step of widening a yarn width according to one of the above methods; and a sticking step of heating the woven fabric to the softening point or melting point of the low melting point resin fiber or higher to stick the reinforcing fibers with each other or a reinforcing fiber and an auxiliary yarn by the low melting point resin.
  • the method further comprises the step of applying and adhering a powdery or fibrous resin on one side or both sides of the reinforcing fiber woven fabric, and the adhering amount of the resin is 2 to 20% by weight of the woven fabric.
  • the apparatus for producing the reinforcing fiber woven fabric of the invention is as follows.
  • An apparatus for producing a reinforcing fiber woven fabric comprises: a guide roller which comes into contact with the surface of a reinforcing woven fabric continuously passing through at a predetermined winding angle and rotates; a plurality of cylindrical bodies rotatably supported on the woven fabric which comes into contact with the surface of the guide roller; and a driving part for reciprocating the cylindrical bodies in the direction of the warp of the woven fabric.
  • the cylindrical body has a diameter of 10 to 40 mm and a length of 10 to 50 mm, and cylindrical bodies are alternately staggered in the direction of the warp of the woven fabric.
  • FIG. 1 is a perspective view for explaining the method for producing a reinforcing fiber woven fabric 1 using a yarn width widening method as the feature of the invention.
  • numeral 1 designates a woven fabric 1 using a reinforcing woven fabric for a fiber reinforced plastic, and a so-called bi-directional woven fabric 1 obtained by interlacing a warp 2 and a weft 3 of a reinforced yarn each other and weaving them. Since the bi-directional woven fabric 1 itself can be woven by a known method, such as using a rapier loom, the explanation to the weaving step is omitted herein.
  • Numeral 4 designates a cylindrical body for widening the woven fabric 1 in the direction of the weft 3 (the direction of an arrow A of FIG. 1 ) and having a dumbbell shape.
  • a plurality of cylindrical bodies 4 are arranged in parallel so that the rotating shafts are corresponded to the direction of the weft 3 of the woven fabric 1, and the woven fabric 1 is widened by reciprocating the cylindrical bodies 4 in the direction of the warp 2 (the direction of an arrow B) in the pressurization state of a suitable pressing force to the woven fabric 1.
  • the width of the each weaving yarns is widened by the widening step, and thereby a uniform woven fabric 1 having no gap between the weaving yarns is obtained.
  • the woven fabric 1 canbepressurized, for example, by a spring or an air cylinder.
  • the widening effect is preferably large when the pressure force is high as much as possible, there is a problem which shags are generated when the pressure force is too high and particularly the reinforcing fiber is the carbon fiber, and the load of 100 to 2000 g per 1 cm of the length of the cylindrical body 4 is preferably applied in a direction perpendicular to the surface of the woven fabric 1.
  • the reciprocation of the cylindrical body 4 is mechanically limited, and the speed of the reciprocation (the product of amplitude (mm) and frequency (time/second)) is preferably 50 to 300 mm/second. So as to reciprocate the same parts of the woven fabric 1 frequently as much as possible in such speed range, sequences of plural cylindrical bodies 4 are arranged. Thereby, reciprocation with the plural cylindrical bodies 4 results in the same movement with passing though the same parts of the woven fabric 1 plural times, and the high effect is obtained in spite of less frequency.
  • the widening effect can be obtained by the method for reducing the amplitude to enlarge the frequency as the widening condition, it is necessary to widen the woven fabric 1 in the range where the widening operation is very short distance, and thereby the woven fabric 1 cannot be fully widened.
  • the width can be uniformly and greatly widened.
  • the amplitude is preferably 10 to 100 mm, and more preferably about 20 to about 50 mm.
  • FIG. 1 shows the case where the woven fabric 1 is in a rest state, and in this case, the cylindrical body 4 is sequentially moved in the direction of the arrow C while the cylindrical body 4 is reciprocated in the direction of the arrow B, and the woven fabric 1 can be moved off by a suitable means when the yarn width widening of a woven fabric 1 interval is completed.
  • the cylindrical body 4 may be reciprocated while being rolled, the cylindrical body 4 may be moved to one direction without reciprocating. It is preferable to move the cylindrical body 4 while reciprocating since large effect is obtained by the movement passing through the same parts of the woven fabric 1 plural times.
  • FIG. 2 is a partial sectional view for explaining a widening principle for widening the weaving yarn in the width direction, and shows a cutting plane in the direction of the weft 3 of the woven fabric 1 coming into contact with the cylindrical body 4.
  • the narrow width W1 of the warp 2 means that the section of the reinforcing fiber bundle has the ellipse form closed to circular and the woven fabric 1 has a shape swelling up to the thickness direction.
  • the swelling portion is vertically pressurized in the direction of an arrow by the cylindrical body 4 to the surface of the woven fabric 1, the reinforcing fiber bundle of the warp 2 is pushed out in the direction of the weft 3.
  • FIG. 2 is a partial sectional view for explaining a widening principle for widening the weaving yarn in the width direction, and shows a cutting plane in the direction of the weft 3 of the woven fabric 1 coming into contact with the cylindrical body 4.
  • the narrow width W1 of the warp 2 means that the section of the reinforcing fiber bundle has
  • the yarn width of the weft 2 is widened and is set to W2.
  • the yarn width of the warp 2 can be sequentially widened in the direction of the weft 3.
  • both the warp 2 and the weft 3 are a reinforcing fiber and the warp 2 and the weft 3 interlace each other, the warp 2 and the weft 3 resist the widening of the yarn width due to the interlace. Thereby, it is difficult to widen the yarn width until the gap between the weaving yarns is completely eliminated by only one movement of the cylindrical body 4.
  • a means for making the cylindrical body 4 passing through the same parts several times to sequentially widen the yarn width is preferable, and therefore, it is preferable to reciprocate the cylindrical body 4 in the direction of the warp 2.
  • the yarn width of various reinforcing fiber woven fabrics can be fully widened by the above principle, the binding force of the warp 2 and weft 3 is strong and the weaving yarns are hardly moved in the case of a usual woven fabric in which the weaving yarns 2, 3 are woven at high density and are firmly interlaced each other.
  • the method of the invention exhibits the effect when producing the flat yarn woven fabric 1 woven by the thick non-twist reinforcing fiber yarn having the fineness of, particularly, 400 to 4,000 TEX, and which is a low areal weight woven fabric 1 of 80 to 300 g/m 2 woven in the large pitch of the weaving yarn of 5 to 32 mm. That is, though the weaving yarns converged during weaving become narrower easily and cause a gap between the weaving yarns in the low areal weight woven fabric consisting of the thick reinforcing fiber yarn, the occurrence of such gap is prevented according to the method of the invention, and the woven fabric 1 having no gap between the weaving yarns can be manufactured.
  • the reinforcing fiber yarn used for the method for producing the reinforcing fiber woven fabric 1 of the invention a carbon fiber, a glass fiber, an aramid fiber, a synthetic fiber having high strength or the like can be used.
  • the carbon fiber having high specific tensile strength and specific modulus is preferable.
  • the flat state is crushed by the following factor in the weaving step, and the woven fabric 1 cannot be made by keeping the nearly same yarn width as that of the weaving yarn pitch.
  • the weaving yarn ends up with narrower in width, and the woven fabric 1 having the gap between the weaving yarns is made.
  • the producing method of the invention widens the weaving yarn while rolling the cylindrical body 4 in the pressurization state, the producing method has a feature that the yarn width can be widened even if the sizing agent is adhered to the carbon fiber yarn and the fibers are adhered with each other.
  • this feature is effective for widening the yarn width of the reinforcing fiber consisting of the carbon fiber yarn to which a sizing agent of 0.5 to 2.0% is adhered.
  • the above formula shows that the woven fabric 1 should have the weaving yarn pitch comparatively small when using the carbon fiber yarn having the small fineness and woven fabric 1 should have the large weaving yarn pitch when using the carbon fiber yarn having the large fineness.
  • the above range of the constant k is important in the flat yarn woven fabric 1 to which the above formula is applied.
  • the constant k of less than 18 ⁇ 10 2 reduces the weaving yarn pitch, and the flat yarn woven fabric 1 gets close to the usual carbon fiber woven fabric. Since the woven fabric has small gap formed between the weaving yarns, the woven fabric 1 has no necessity of widening of the width of the weaving yarn.
  • the weft consisting of an auxiliary yarn in the uni-directional woven fabric is mainly used for integrating the warp 2 arranged by interlacing with the reinforcing fiber yarn.
  • the weft 3 as the auxiliary yarn is preferably the thin yarn so as to reduce the crimp of the reinforcing fiber yarn due to the interlacing as much as possible.
  • the weft 3 is the thin yarn of less than 1 TEX
  • the force for integrating the warp 2 of the reinforcing fiber lacks, and the weft 3 is cut by the small external force. Thereby, the object of the integration cannot be attained.
  • the fineness of the weft 3 exceeds 30 TEX, the crimp is generated in the warp 2 of the reinforcing fiber yarn by the interlacing, or the weft 3 is generated in the convex shape on the surface of the reinforcing fiber ending up with making the surface unevenness larger.
  • the fineness of the weft 3 is preferably 1 to 10 TEX.
  • the weft 3 of the uni-directional woven fabric 1 in the invention has the very thin fineness and the binding force in the interlacing part of the warp yarn and weft yarn is small.
  • the constant k is preferably 0.01 to 0.28 as a value smaller than the above case.
  • the method for producing the reinforcing fiber woven fabric 1 using the method for widening the yarn width as the feature of the invention widens the yarn width while rolling the cylindrical body 4 in the pressurization state on the woven fabric 1.
  • the producing method of the invention reciprocates the cylindrical body 4 in the direction of the warp yarn to widen the width. Since the section of the yarn bundle in which filaments gather referring to the warp 2 is continuously and sequentially widened in the yarn axial direction, the yarn width can be effectively widened. However, since the section of the yarn bundle is only momentarily crushed referring to the weft 3, the widening effect is less than that of the warp 2.
  • the cylindrical body 4 can be smoothly rolled by the method for widening the warp 2 by the cylindrical body 4 and that is preferable because the yarn width of the warp 2 and weft 3 can be certainly widened.
  • a nozzle having air injection holes having a diameter of 0.2 to 0.5 mm and arranged in the pitch of several mm is provided so as to face the surface of the woven fabric 1 in parallel with the direction of weft 3 of the woven fabric woven 1 on the loom, and the weft 3 is opened and the yarn width is widened at the same time when the woven fabric 1 passes while injecting air.
  • the weft 3 since the winding tension is applied to the warp 2, it is difficult to widen the yarn width of the warp 2 by the air jet.
  • the weft 3 is previously opened, the yarn width of the narrow warp 2 can be opened while the cylindrical body 4 is smoothly rotated. Simultaneously, aportionwhere the spread is a little insufficient can be also widened by the air opening.
  • the weave style is not particularly limited, and may be the plain weave, the twill weave and the satin organization.
  • the plain weave in which the warp 2 and the weft 3 interlace alternatively is preferable since it is hard to generate the woven fabric 1 slippage.
  • the weaving yarn is heated after the weaving yarn is widened by the above widening method of reciprocating the cylindrical body 4 in the direction of the warp 2 of the woven fabric 1 while rolling the cylindrical body 4 in the pressurization state to woven fabric 1 on the woven fabric 1 into which the low melting point resin fiber is inserted.
  • the weaving yarn is adhered in a state where the weaving yarn is widened, and the molding material of woven fabric 1 in which the reinforcing fiber is uniformly dispersed can be provided, which has excellent handling without changing the woven fabric structure at the time of future handling can be provided.
  • the method of inserting the low melting point resin fiber there is a method in which the resin fiber is pulled, arranged and supplied to the warp 2 and/or the weft 3 of the carbon fiber at the time of weaving in the case of a bi-directional woven fabric 1.
  • the low melting point resin fiber is pulled and arranged together with the auxiliary yarn.
  • the insertion can be secured by using a covering yarn which has a core/ sheath configuration as the auxiliary yarn and by making the sheath portion of the low melting point resin fiber.
  • the core yarn of the covering yarn having a core/sheath configuration is preferably the fiber yarn which causes almost no heat shrinkage at the heating temperature at the time of performing the heat fusion of the low melting point resin and has the shrinkage percentage of 1% or lower in the dry heating condition of 150°C.
  • the core yarn is preferably the thin fineness yarn consisting of a glass fiber, an aramid fiber yarn or a vinylon fiber.
  • low melting point resins examples include copolymer nylon and copolymer polyester having a melting point of 90 to 180°C.
  • a reinforcing material in which reinforcing fiber is uniformly dispersed can be provided by applying and adhesion of the powdery or fibrous resin after the widening step of the weaving yarn similarly, even when a woven fabric 1 is going to be stabilized, be piled up and adhere each other, or undergo to the interlayer toughening by applying and adhesion of the powdery or fibrous resin on one side or both sides of the woven fabric.
  • the resins for being applied and adhered include a thermosetting resin or a thermoplastic resin.
  • the thermosetting resin include epoxy, phenol, unsaturatedpolyester, vinylester, and a resin including a curing agent or a catalyst.
  • the thermoplastic resins include polyester, polyamide, polyurethane, polyether sulfone, a copolymer a modifier and a mixture of two or more kinds thereof.
  • the adhering amount of the powdery or fibrous resin at this time is preferably 2 to 20% by weight although it is according to the object.
  • the adhering amount of the resin is preferably larger in view of the form stability of the woven fabric 1.
  • the adhering amount of the resin exceeds 20% by weight, the whole surface of the woven fabric 1 is covered by the resin, and the impregnation of a matrix resin is inhibited in the case of the injection-mold of the resin.
  • the adhering amount of the resin exceeding 20% by weight requires for the impregnation for a long time, and a non-impregnation part is formed.
  • the adhering amount of the resin is less than 2% by weight, the powdery or fibrous resin cannot be uniformly dispersed on the surface of the woven fabric 1. Since parts where the reinforcing fibers do not adhere each other exist, the shape retainability of the woven fabric 1 is inadequate, the optimal adhering amount is the above range.
  • the resin can be adhered on the surface of the woven fabric 1 by uniformly applying the powdery resin on the woven fabric 1 in which the yarn width of the weaving yarn is widened and heating it when the powder is used as the resin in the method of applying or adhering it on the woven fabric 1.
  • the resin can be also adhered by passing the woven fabric 1 through a heating roller.
  • the resin can be adhered on the woven fabric 1 by heat fusion or needling in the case of using the fiber as the form of the non-woven fabric.
  • FIG. 3 is a perspective view of the preferred arrangement example of the cylindrical body 4 of FIG. 1 .
  • the yarn width of each yarn constituting the woven fabric 1 is continuously widened by reciprocating the cylindrical body 4 with a fixed amplitude in the direction of the warp 2 on the woven fabric 1 coming into contact with the guide roller 5 while moving the woven fabric 1 in a C direction of FIG. 3 along the surface of the guide roller 5 capable of being rotated.
  • the cylindrical body 4 is rotatably supported by a suitable roller bearing to the both ends of one shaft, and the cylindrical body 4 can be reciprocated in the direction of the warp 2 by a means for supporting the central part of the axis and reciprocating.
  • the pressure force to the woven fabric 1 can be suitably adjusted by a forcing means.
  • the cylindrical guide roller 5 is a rotating roller having a diameter of about 100 to about 500 mm and having a smooth surface, and the guide roller 5 is passively rotated according to the movement of the woven fabric 1 by the frictional force when the woven fabric 1 comes into contact with the surface of the guide roller 5.
  • the woven fabric 1 is abutted at a suitable winding angle to the peripheral curved surface of the guide roller 5, the tensility in the direction of the warp 2 of the woven fabric 1 acts in the direction of the central axis of the guide roller 5. Therefore, the high friction force acts on the contacting surface of the guide roller 5 and woven fabric 1, and the weft 3 of the woven fabric 1 is not shifted even when the cylindrical body 4 (widening roller) is reciprocated over the woven fabric 1 and the weaving yarn can be widened.
  • the length of the cylindrical body 4 is preferably 10 to 200 mm, and more preferably 10 to 50 mm.
  • Two cylindrical bodies 4 are attached to the both ends of a shaft in a state where the cylindrical bodies 4 can be rotated by bearings. Since each shaft supports the central part and the load acts, uniform pressure can be put on the woven fabric 1 by each roller.
  • two of the cylindrical bodies 4 of a two-piece unit are arranged in one sequence, and are arranged as one group in back to front two sequences.
  • the cylindrical bodies 4 of a two-piece unit are alternately staggered in the direction of the movement of the woven fabric 1, and thereby the weaving yarn can be uniformly widened over the full width of woven fabric 1.
  • the movement speed in B direction of the woven fabric 1, that is, the weaving speed of the woven fabric 1 is preferably low speed as much as possible since the speed of the reciprocation of the cylindrical body 4 is mechanically limited.
  • the range of 0.2 to 2.0 m/min is preferable for the range which does not influence manufacture cost.
  • FIG. 5 is a partial side view of an apparatus for reciprocating a pair of the widening rollers 4 of back to front two unit in the direction of the warp 2 while forcing with the suitable pressure to the surface of the woven fabric 1 on the guide roller 5.
  • the central part of the shaft to which the cylindrical body 4 is attached is fixed to a horseshoe-shaped supporting arm 6, and the cylindrical bodies 4 of four units are attached to one supporting arm 6.
  • Each supporting arm 6 is coupled with the pressing member 8, and the pressing member 8 performs a crank reciprocation around a rotation shaft O by a reciprocation drive coupling rod 7 .
  • the driving member 8 can perform a rocking movement in parallel in a concentric circle shape with the circle of the guide roller 5 by the guide 9 (not shown), and the compression spring 10 is interposed between the supporting arm 6 and the pressing member 8, and the pressure of the cylindrical body 4 is applied to one surface of the woven fabric 1 in the pressing operation in the direction of the roller 5 of the compression spring 10.
  • the diameter of the cylindrical body 4 is preferably is smaller as much as possible since high linear pressure can be applied by the same pressing load, the minimum diameter is determined from the bearing size since a bearing is incorporated in so as to make the rotation smooth.
  • the diameter of the cylindrical body 4 is 12 to 60 mm, and more preferably 12 to 20 mm.
  • the diameter of the cylindrical body 4 is preferably smaller as much as possible since high linear pressure is generated even in the same pressing load. However, when the diameter is set to less than 12 mm, a small bearing is formed and the cylindrical body 4 cannot sustain the high pressure. Thereby, it is necessary to set the diameter to 12 mm or more.
  • the length of the cylindrical body 4 is larger in view of the manufacture side, the length is preferably 200 mm or less so as to uniformly disperse the load in the longitudinal direction of the cylindrical body 4 and more preferably 50 mm or less.
  • the surface of the cylindrical body 4 is a preferably a smooth surface so as not to damage the carbon fiber, and the end part is preferably chamfered. Since particularly, the carbon fiber having high elastic modulus is brittle and easily damaged, the surface of the cylindrical body 4 may be coated with a rubber.
  • the woven fabric 1 uses reinforcing fiber yarns as the warp 2 and the weft 3, and the thick non-twist reinforcing fiber yarn having the fineness of 400 to 4,000 TEX is arranged in a large pitch.
  • the fineness and weaving yarn pitch of the reinforcing fiber yarn have the following relationship.
  • the opening ratio produced at the interlacing part of the warp 2 and weft is 0.3 or less, and the size of an opening part is 1 mm 2 or lower.
  • P k • T 1 / 2 wherein
  • the fiber reinforced plastic having high specific tensile strength and specific modulus is preferably obtained.
  • the low fiber areal weight carbon fiber woven fabric having the fiber areal weight of 80 to 300 g/m 2 which is conventionally woven by the thin carbon fiber yarn of fineness of 200 TEX or less, with the thick carbon fiber having the fineness of 400 to 4, 000 TEX, the productivity of the woven fabric 1 increases 2 to 20 times. Also, the manufacture cost of the thick carbon fiber yarn is inexpensive, the carbon fiber woven fabric 1 of low cost can be provided.
  • the weaving yarn section of the thick carbon fiber has a flat shape and the weaving yarns interlace each other, the carbon fiber reinforced plastic having small crimp of the weaving yarn and exhibiting high mechanical property is expected.
  • the woven fabric 1 which, has no gap between the weaving yarns and in which the carbon fiber is uniformly dispersed while keeping the flat shape of the thick carbon fiber flat yarn, and the woven fabric 1 in which the opening part is formed in the interlacing part of the warp 2 and weft 3 is made.
  • the opening part produced in the interlacing part of the warp 2 and weft 3 can be reduced by the yarn width widening method described above, and the woven fabric 1 for reinforcement exhibiting the excellent mechanical property is obtained.
  • the above opening ratio can be get by sampling from three different places of a woven fabric having the length of 1 m so as to include at least ten or more of the warp 2 and weft 3 and by measuring the interval and the width of ten of the warp 2 and the weft 3 at each sample by a slide caliper by 0.1 mm.
  • the opening area is the value of the numerator of the above formula.
  • a yarn interval is the distance between the central lines of adjoining weaving yarn, the yarn interval should be the distance between the end part of the yarn width direction and the end part of the adjoining yarn when the opening ratio and opening area are calculated in the invention.
  • the opening ratio of the woven fabric 1 of the invention is 0.3% or less, and the area of one opening part is 1 mm 2 or less.
  • the opening part can contain the resin only to the film thickness when the surface tension of the resin acts.
  • the flat carbon fiber yarn of the neighbors of the opening part is roundly converged, and the opening part is greatly opened to form prepreg.
  • the opening part can contain the resin sufficiently. Since the surface tension acts also to the resin existing in the opening part at the time of dryness of the solvent, the opening part is not enlarged.
  • the carbon fiber flat yarn having the number of filaments of 12,000, the tensile strength of 4800 MPa, the tensile elastic modulus of 230 GPa and the yarn width of 6 mm is used as the warp 2 and the weft 3.
  • the flat yarn woven fabric 1 having the flat organization is woven by a rapier loom at the number of rotations of 80 RPM and the density where the weaving yarn pitches of the warp 2 and the weft 3 are respectively set to 8.3 mm.
  • theweft3 is opened and widened by an air jet injection of a supply air pressure of 0.5 Pa.
  • the widening process is then performed by the widening method due to the cylindrical body 4 explained in FIG. 5 .
  • the pressing load to the widening roller 4 is set to about 200 g per the length of 1 cm of one widening roller.
  • the widening rollers are arranged at four sequences, and the amplitude (the direction of B of figure) is set to 50 mm.
  • the frequency is set to two times / second.
  • the diameter and the length are respectively set to 12 mm and 15 mm.
  • Table 1 The evaluation results of the woven fabrics 1 before and after air jet process and woven fabric 1 whose yarns are widened by the widening method due to the cylindrical body 4 of the invention are shown in Table 1.
  • the width of the weft 3 is largely widened by the air jet process
  • the width of the warp 2 is slightly narrow by the air jet process
  • the width of the warp 2 is largely widened in the direction of A by the yarn width widening method due to the widening roller process.
  • the woven fabric 1 in which the widths of both the warp 2 and the weft 3 are widened and which is very uniform having no gap in the interlacing part of the warp 2 and weft 3 is obtained.
  • the woven fabric has openings at the interlacing part of the warp and the weft since the width of the warp is narrow, where the openings are smaller than that of the woven fabric of Comparative Example 1.
  • the woven fabric has the opening ratio of 0.4%. Although the opening ratio of the woven fabric of Comparative Example 2 is small, the width of the warp is narrow, thus the warp part is projected to the surface of the woven fabric and the woven fabric has the uneven surface.
  • Table 1 Manufacture Condition The Warp The Weft Opening ratio (%) Area of Maximum Opening Part (mm 2 ) Air Opening Widening of the Invention Weaving Yarn Interval Yarn Width (mm) Weaving Yarn Interval (mm) Weaving Yarn Interval Yarn Width (mm) Weaving Yarn Interval (mm) Example 1 Presence Presence 8.3 7.9 8.3 8.3 0 0 Comparative Example 1 None None 8.3 7.1 8.3 6.4 3.3 4.5 Comparative Example 2 Presence None 8.3 6.9 8.3 8.1 0.4 1.5
  • the width of the weaving yarn can be effectively widened in the width direction of the woven fabric 1 since the production method and the apparatus put a woven fabric 1 consisting of the reinforcing fiber in the pressurization state by the cylindrical bodies 4 rolling and reciprocating in the direction of the warp 2. Therefore, the fiber reinforced plastic product in which the reinforcing fiber is uniformly dispersed can be obtained as the base material for reinforcement of end products.
  • the widening method used in the method for producing the reinforcing fiber woven fabric 1 of the invention is a method in which a cylindrical body 4 is reciprocated to the woven fabric 1 while rolling in the direction of the warp 2 to widen the width of the weaving yarn even when the reinforcing woven fabric 1 is the woven fabric 1 in which woven fabric 1 slippage is easily generated as in the flat yarn woven fabric 1 made of the carbon fiber.
  • the yarn width can be securely widened without disturbing the arrangement of the weaving yarn as in the prior art. Therefore, the woven fabric having no gap between the weaving yarns can be obtained.
  • the yarn width widening processing can be continuously performed on the loom.
  • the producing method and apparatus for the invention can be widely used in fields such as the airplane member and the general industrial use.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Materials For Medical Uses (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Reinforced Plastic Materials (AREA)

Claims (18)

  1. Verfahren zur Herstellung eines faserverstärkten Gewebes (1), bei dem eine Verstärkungsfaser als zumindest ein Kettfaden (2) gewebt wird, wobei das Verfahren den Schritt umfasst:
    Hin- und Herbewegen eines zylindrischen Körpers (4) in der Richtung des Kettfadens (2) des Gewebes (1) auf dem Gewebe (1), während der zylindrische Körper (4) in einem druckbeaufschlagten Zustand zum dem Gewebe (1) gerollt wird, um die Fadenbreite zumindest des Kettfadens (2), der das Gewebe (1) bildet, in der Richtung eines Schussfadens (3) zu verbreitern,
    dadurch gekennzeichnet, dass
    der zylindrische Körper (4) auf dem Gewebe (1) hin- und herbewegt wird, das mit einer Führungswalze (5) in Kontakt gelangt, während das Gewebe (1) entlang der Oberfläche der Führungswalze (5), die gedreht werden kann, bewegt wird.
  2. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 1, wobei die Druckkraft des zylindrischen Körpers (4) auf das Gewebe (1) 100 bis 2000g pro 1 cm der Länge in der axialen Richtung des zylindrischen Körpers (4) beträgt.
  3. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 2, wobei eine Verbreiterungsrate zum Verbreitern der Fadenbreite des Kettfadens (2) in der Richtung des Schussfadens (3) 2 bis 50 % beträgt.
  4. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 1, wobei dicke Verstärkungsfaserfäden ohne Verdrehung, die eine Feinheit von 400 bis 4000 TEX aufweisen, in einem Webfadenabstand von 5 bis 32 mm angeordnet sind, und die Feinheit und der Webfadenabstand des Verstärkungsfaserfadens die folgende Relation erfüllen: P = k • T 1 / 2
    Figure imgb0009
    wobei P der Webfadenabstand (mm) ist,
    T die Feinheit der Verstärkungsfaser (TEX) ist,
    k (18 bis 50) x 10-2 ist.
  5. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 1, wobei dicke Verstärkungsfaserfäden ohne Verdrehung, die eine Feinheit von 400 bis 4000 TEX aufweisen, in einem Webfadenabstand von 4 bis 16 mm angeordnet sind;
    das Gewebe (1) ein einseitig gerichtetes Gewebe (1) ist, das durch den Schussfaden (3) eines dünnen Hilfsgarns mit einer Feinheit von 1 bis 30 TEX integriert ist; und
    die Feinheit und der Webfadenabstand des Verstärkungsfaserfadens die folgende Relation erfüllen: P = k • T 1 / 2
    Figure imgb0010
    wobei P der Webfaden(Kettfaden)abstand (mm) ist,
    T die Feinheit der Verstärkungsfaser (TEX) ist,
    k (10 bis 28) x 10-2 ist.
  6. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5, wobei die Verstärkungsfaser eine Kohlenstofffaser ist.
  7. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 6, wobei die Anzahl der Filamente der Kohlenstofffaser 6000 bis 50000 beträgt.
  8. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei eine Vielzahl von zylindrischen Körpern (4) abwechselnd in der Richtung des Kettfadens (2) versetzt angeordnet sind, um die Fadenbreite des Gewebes (1) zu verbreitern.
  9. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei das Gewebe (1) in der Richtung des Kettfadens (2) entlang der Oberfläche der Führungswalze (5), die gedreht werden kann, bewegt wird, um die Fadenbreite des Gewebes (1), das mit der Oberfläche der Führungswalze (5) in Kontakt gelangt, ständig zu verbreitern.
  10. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei die Fadenbreite zwischen einem Stoffrand eines Webstuhls und einer Wickelrolle des Gewebes (1) verbreitert wird.
  11. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei eine Durchschnittsgeschwindigkeit zum Hin- und Herbewegen des zylindrischen Körpers (4) 50 bis 300 mm/Sekunde beträgt.
  12. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei der zylindrische Körper (4) auf dem Gewebe (1) gerollt wird, bevor das Gewebe (1) mit Harz imprägniert wird.
  13. Verfahren zur Herstellung eines faserverstärkten Gewebes (1), wobei das Gewebe (1) ein Flachgarngewebe (1) mit einem Kettfaden (2) und einem Schussfaden (3) bestehend aus einem Kohlenstofffaserfaden ist, und ein flaches Gewebe (1) mit Grundbindung aufweist, wobei das Verfahren die Schritte umfasst:
    Öffnen und Verbreitern des Schussfadens (3) durch Luftstrahleinspritzung aus Einspritzlöchern, die in der Richtung des Schussfadens (3) des Gewebes (1) angeordnet sind, und
    Verbreitern der Kettfadenbreite in der Richtung des Schussfadens (3) durch das Verfahren nach einem der Ansprüche 1 bis 5 oder 7.
  14. Verfahren zur Herstellung eines faserverstärkten Gewebes (1), wobei das Verfahren umfasst:
    einen Webschritt des Webens eines Gewebes (1), während eine Harzfaser mit niedrigem Schmelzpunkt in der Richtung eines Kettfadens (2) oder eines Schussfadens (3) zugeführt wird;
    einen Verbreiterungsschritt des Verbreiterns einer Fadenbreite durch das Verfahren nach einem der Ansprüche 1 bis 5 oder 7; und
    einen Klebeschritt des Erwärmens des Gewebes (1) auf den Erweichungspunkt oder Schmelzpunkt der Harzfaser mit niedrigem Schmelzpunkt oder stärker, um die Verstärkungsfasern miteinander oder eine Verstärkungsfaser und ein Hilfsgarn durch das Harz mit niedrigem Schmelzpunkt zu verkleben .
  15. Verfahren zur Herstellung des faserverstärkten Gewebes (1) nach einem der Ansprüche 1 bis 5 oder 7, wobei es ferner den Schritt des Aufbringens und Anhaftens eines puderförmigen oder feinfasrigen Harzes auf einer Seite oder beiden Seiten des faserverstärkten Gewebes (1) umfasst, wobei die Anhaftungsmenge des Harzes 2 bis 20 Gew.% des Gewebes (1) beträgt.
  16. Vorrichtung zur Herstellung eines faserverstärkten Gewebes (1), wobei diese umfasst:
    eine Führungswalze (5), die mit der Oberfläche eines faserverstärkten Gewebes (1), das fortlaufend mit einem vorbestimmten Wickelwinkel hindurch läuft, in Kontakt gelangt und dreht;
    eine Vielzahl von zylindrischen Körpern (4), die drehbar auf dem Gewebe (1) gelagert sind, das mit der Oberfläche der Führungswalze (5) in Kontakt gelangt; und
    ein Antriebsteil zum Hin- und Herbewegen der zylindrischen Körper (4) in der Richtung des Kettfadens (2) des Gewebes (1).
  17. Vorrichtung zur Herstellung des faserverstärkten Gewebes (1) nach Anspruch 16, wobei der zylindrische Körper (4) einen Durchmesser von 10 bis 40 mm und eine Länge von 10 bis 50 mm aufweist, und die zylindrischen Körper (4) abwechselnd in der Richtung des Kettfadens (2) des Gewebes (1) versetzt angeordnet sind.
  18. Vorrichtung nach einem der Ansprüche 16 oder 17, ausgelegt zur Herstellung eines faserverstärkten Gewebes (1), wobei der zylindrische Körper (4) auf einem Gewebe (1) gerollt wird, bevor das Gewebe (1) mit Harz imprägniert wird.
EP03818577A 2003-09-05 2003-09-05 Verfahren und vorrichtung zur herstellung eines verstärkungsgewebes Expired - Lifetime EP1662033B1 (de)

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JP5425380B2 (ja) * 2007-08-10 2014-02-26 株式会社有沢製作所 織物の開繊方法
CN101910484B (zh) * 2008-01-11 2012-08-15 东丽株式会社 织物以及使用该织物制成的衣服
FR3002928B1 (fr) 2013-03-08 2015-05-01 Hexcel Reinforcements Procede et machine d'etalement d'une nappe textile de type tissu et tissus obtenus
JP6024858B1 (ja) * 2015-05-08 2016-11-16 東レ株式会社 合糸糸条束の製造方法および得られた合糸糸条束を用いる炭素繊維の製造方法
CN107385594A (zh) * 2016-04-05 2017-11-24 旭化成株式会社 复合纱线和布帛以及它们的制造方法
TWI697597B (zh) * 2020-02-21 2020-07-01 福濃機械股份有限公司 可調整撓度的展布裝置及其調整撓度的方法
US12173431B2 (en) * 2021-12-20 2024-12-24 Rtx Corporation Fabric structure control using ultrasonic probe

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DE60335041D1 (de) 2010-12-30
ATE488631T1 (de) 2010-12-15
WO2005024111A1 (ja) 2005-03-17
AU2003261953B2 (en) 2009-11-26
EP1662033A1 (de) 2006-05-31
AU2003261953A1 (en) 2005-03-29
US7779870B2 (en) 2010-08-24
CN100543218C (zh) 2009-09-23

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